2005 Tacoma Frame Crack

Not to start a new thread on an old topic, but here it is.
Back history on my truck, 2005 Tacoma double cab v6 6speed daily driver. It does have a leveling kit and 285s on it
Fan was rubbing on lower drivers side section of the shroud and was driving me crazy, checked and from the top of the mount you can not really see any damage besides a bad motor mount. As I was tight on cash I held off for a couple months and it progressively got worse, therefore I finally replaced it and the trans mount as both were torn. Still having the issue. So I look up the problem and of course find a few threads on it. Obviously I go look, and exactly what I find is the worst frame tear of any of the ones I've seen online so far. That being said what have we been doing to address this situation? Weld and gusset it? Have toyota fix it? Insurance claim? My guess is it shouldn't be totaled and if so I have an amazing welder that does all of our aluminum boats at work. Looks like if it's fixed though it will get a TC gusset kit...

 

dear god.....

 

Holy crap!!

 

Less than awesome

 

so ill add some help. If your abilities allow you to that is, do this.

Pull motor, pull out mounts to factory alignment, weld, add the aftermarket support kit. If your not comfortable with that, pay a shop..

 

Holy shit that's awesome

 

x2
Sorry op

 

Buried in the 05 Motor mount thread somewhere, there is mention of a gusset kit made specifically for this problem. I think the company is based in San Diego. DMZ fab maybe? I would have your welder jack the motor up until the frame mounts are back in position, weld the crack, then install the gusset kit. It looked really stout, well designed. Toyota usually won't help anyone on this, and insurance isn't going to pay unless there was an accident.

 

I do have the means to pull motor as my father owns a local repair shop with all necessary tools including a lift and hoist. I just hate to pull the motor really. If I can just have the motor hoisted up and do it I will. My plan would be to plate both sides, weld and then gusset it. Total chaos makes a gusset kit for it as well. TC is my first choice for long travel which is my plan down the road anyways, so might as well now go with their gusset kit. Sucks i didn't see this sooner... Hard to believe all the lt threads didn't make this a point with how many people that beat the hell out of these. I am going to call into Toyota and definitely make my point regardless of their decision. I will also let my local dealer know, as much help as they usually are. At least I have a motorcycle to use as a dd. Just a lil bummed for the most part.

 

customer of mine had this problem back in 06 and had the frame replaced by toyota. i would go to the dealership and see what they say.

 

Actually can't find the tc kit now... I was almost sure I saw it when looking for LT kits

 

If I can get it done I will have Toyota cover it, as clearly they fixed it in 07...

 

Have you at any point has a fat chick in the truck bed jumping up and down?

 

Crap! I told them they were gonna break it! Haha

Other than that I flipped through the other thread and I misremembered and solo motorsports out of Covina ca is actually the shop that makes the kit, gonna hit them up Monday as well. I'm not happy by any means, and hate to say it but may not brag as highly as I do about my taco anymore. That being said this is the only issue I've ever had in the over 60k miles I've owned it.

 

Have most people been having this problem in relation to rust? That would make more sense as it would weaken the welds. This is a very low corrosion Arizona truck and it should not have been affected.

 

The way I understand it, there are two separate issues here:

1. Weak design. The 2005-mid2007ish Tacoma, 03-09 4Runner, and FJ Cruisers up until, I think, 2010 all have the same weak design. The people who are having issues are typically wheeling the snot out of their trucks.

2. There is also an issue with early 2005 Tacomas, built in 2004, up to some point in 2005. The welding machinery was not set up properly and the welds were "undercut" into the base metal. (too much power cranked up on the welder). The owners of these trucks are having issues even when driving to the grocery store and to church.......etc.

What month/year was yours built? I'd bet it's early production from the stories I have read on here.

 

DMZ out of Corona makes the original gusset kit
WWW.dmzfab.com

 

Update, truck is at the dealership waiting to be inspected tomorrow. Supposedly the Toyota field technical specialist is going to be here tomorrow, so they are gonna have him look at it tomorrow. I hope they are going to shoot straight with me, I've heard some negative things about them.